Process of reacting isocyanates with active hydrogen containing compounds using sulfonium zwitterions as initiators

Claim 2

A process for reacting an organic isocyanate with an active hydrogen compound, which comprises contacting the reactants with an ar-sulfonium areneoxide present in an amount and under conditions sufficient to initiate the reaction of said reactants.

Claim 3

The process of claim 1 wherein the isocyanate is partially trimerized to form a NCO-terminated isocyanurate oligomer.

Claim 4

The process of claims 1 or 2 wherein the isocyanate is an organic polyisocyanate containing at least two isocyanate groups per molecule.

Claim 5

The process of claim 3 wherein the polyisocyanate is 2,4-toluene diisocyanate, 2,6-toluene diisocyanate, 1,3-bis(isocyanatomethyl)benzene, hexamethylene diisocyanate, 4,4'-diisocyanatophenyl methane, 4,2'-diisocyanatophenyl methane, 2,2'-diisocyanatophenyl methane and mixtures thereof.

Claim 6

The process of claim 1 wherein the ar-sulfonium areneoxide is an ar-sulfonium areneoxide represented by the formula: ##STR23## wherein each Ar is independently a cyclic aromatic polyyl, each R is independently a suitable inert monovalent radical capable of existing as a substituent on Ar, each Z is independently a suitably inert divalent radical capable of bridging aromatic moieties, each R 1 and each R 2 are independently suitably inert monovalent organic radicals and/or each R 1 and R 2 are collectively a suitably inert divalent organic radical capable of forming a heterocyclic ring with ##STR24## a is a positive integer corresponding to the remaining available positions on Ar, b is 0 or a positive integer, and c is 0 or 1.

Claim 7

The process of claim 5 wherein each Ar is a polyyl of benzene, each R is independently H, Cl, Br, OH, R', --OR', --SR', ##STR25## wherein R' is hydrocarbyl or substituted hydrocarbyl wherein the substituents are Cl, Br, --OR' or --SR'; each Z is independently --O--, --S--, ##STR26## --R 3 --, --OR 3 O--, --SR 3 S--, --R 3 O--, --R 3 S-- and ##STR27## wherein R 3 is hydrocarbylene or substituted hydrocarbylene and the substituents are as defined for R; each R 1 and R 2 are individually hydrocarbyl or substituted hydrocarbyl wherein the substituents are as defined in R, or each R 1 and R 2 are collectively hydrocarbylene, substituted hydrocarbylene, heterohydrocarbylene or substituted heterohydrocarbylene wherein the substituents are as defined in R provided that hydrocarbylene or heterohydrocarbylene are of length such that ##STR28## is a 5- to 7-membered ring; b is 0-5, and c is 1.

Claim 8

The process of claim 6 wherein each R is independently H, Cl or alkyl; each Z is independently alkylene, alkylidene, --S--, --O-- or oxyalkyleneoxy, each R 1 and R 2 are individually alkyl or aryl or R 1 and R 2 are collectively alkylene provided that ##STR29## is a 5-membered ring and b is 0 or 1.

Claim 9

The process of claim 1 wherein the ar-sulfonium areneoxide is 4-tetrahydrothiophenium, 2-methylphenoxide, 4-tetrahydrothiophenium 2,6-dimethylphenoxide or 4-tetrahydrothiophenium phenoxide.

Claim 10

The process of claim 1 wherein the isocyanate is reacted with a hydroxyl component.

Claim 11

The process of claim 9 wherein the hydroxyl component is water, a polyol having at least two alkanol groups per molecule or mixtures thereof and the isocyanate is an organic polyisocyanate containing at least two isocyanate groups per molecule.

Claim 12

The process of claim 4 wherein the polyol is an adduct of ethylene oxide, propylene oxide or mixtures thereof with glycerine, ethylene glycol, propylene glycol, dipropylene glycol, trimethylolpropane, pentaerythritol, sorbitol, sucrose or polymer/polyols based on polyether glycols or triols.

Claim 13

The process of claim 10 for producing a polyurethane foam wherein the hydroxyl component is a mixture of water and polyol and the process is carried out such that the gaseous reaction product of the water and isocyanate serve as a blowing agent to produce the polyurethane foam.

Claim 14

The process of claim 1 wherein the ar-sulfonium areneoxide is dissolved in a non-reactive solvent before being contacted with the isocyanate and active hydrogen compound.

Claim 15

The process of claim 1 wherein the reaction is carried out by a reverse addition procedure in which the isocyanate is added to a solution of the ar-sulfonium areneoxide and active hydrogen compound.

Claim 16

The process of claim 10 for preparing an isocyanurate-containing polyurethane wherein in a single step a reaction mixture containing the organic polyisocyanate, the polyol and the ar-sulfonium areneoxide is subjected to reaction conditions such that the areneoxide initiates both the reaction of the polyisocyanate to form an NCO-terminated isocyanurate oligomer and the reaction of the NCO groups of the polyisocyanate and the oligomer with the polyol to form polyurethane.

Claim 17

The process of claim 6 wherein each R 1 and R 2 are independently alkyl groups or substituted alkyl groups having from 1 to 20 carbon atoms.

Claim 18

The process of claim 16 wherein each R 1 and R 2 are independently alkyl groups or substituted alkyl groups having from 1 to 8 carbon atoms.

Claim 19

The process of claim 17 wherein R 1 and R 2 are each selected independently from methyl, ethyl, propyl or butyl groups.

Claim 20

The process of claim 18 wherein each R 1 and R 2 is an ethyl group.

Claim 21

The process of claim 19 wherein the ar-sulfonium areneoxide is 4-diethylsulfonium 2-methyl-phenoxide represented by the formula ##STR30##

Claim 22

The process of claim 17 wherein said substituted alkyl groups are hydroxyl substituted alkyl groups.

Claim 23

The process of claim 1 wherein the ar-sulfonium areneoxide is present in quantities of from about 0.001 to about 0.1 mole per mole of NCO group and the reaction is conducted at a temperature of from about -100° C. to about 130° C.

Claim 24

The process of claim 22 wherein the quantities of ar-sulfonium areneoxide is from about 0.0001 to about 0.001 mole per mole of NCO group and the temperature employed is from about -100° C. to about 100° C.